Vehicle seat with cushioning layer

ABSTRACT

The present invention comprises a seat for a vehicle having at least one temperature conditioned component. The temperature conditioned component comprises a cushion, a trim surface, an insert located beneath the trim surface and a cushioning layer. The cushioning layer comprises one or more pouches with a filler material, and preferably a liquid filler material, that distributes the downward pressure of the occupant across a larger area of the seat. This distribution of downward pressure reduces or eliminates pressure points in the seat. The seat may also include an air mover assembly that facilitates the heating, cooling or ventilation function of the seat by blowing air to or drawing air from the seat.

CLAIM OF PRIORITY

This application claims the benefit of U.S. Provisional Application No.60/736,103, filed on Nov. 10, 2005 and the benefit of U.S. ProvisionalApplication No. 60/784,059, filed Mar. 17, 2006, both of which areincorporated by reference.

FIELD OF THE INVENTION

This invention relates to seats that include heating, cooling orventilation, and more particularly to vehicle seats that include acushioning layer that increases the comfort of the seat.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Various innovations in providing seating comfortare discussed in U.S. Pat. Nos. 6,893,086; 6,872,882; 6,869,139;6,857,697; 6,828,528; 6,676,207; 6,619,736; 6,439,658; 6,164,719;6,064,037; 5,921,314; 6,064,037; 5,921,314; 5,403,065; 6,048,024 and6,003,950, all of which are expressly incorporated herein by reference.In addition, other innovations in providing seating comfort arediscussed in U.S. Publication No. 2002/0096931, filed Jan. 5, 2001,titled “Ventilated Seat”; U.S. Pat. No. 6,629,724, issued Oct. 7, 2003,titled “Portable Ventilated Seat”; U.S. Patent Publication 2004/0070236,filed Oct. 8, 2003, titled “Automotive Vehicle Seating Comfort System”,U.S. Patent Publication 2005/0067862, filed: Apr. 12, 2004, titled“Ventilated Seat”; and U.S. Patent Publication 2005/0066505, filed: Apr.12, 2004, titled “A Method For Ventilating A Seat”, each of which areexpressly incorporated herein by reference for all purposes.

In the interest of continuing such innovation, the present inventionprovides an improved insert and system for a seat, which are preferablysuitable for employment within or as part of an automotive vehicle seatand which assist in providing comfort control to an occupant in theseat.

SUMMARY OF THE INVENTION

The present invention includes a seat for a vehicle having at least onetemperature conditioned component. The temperature conditioned componentcomprises a cushion, a trim surface, an insert located beneath the trimsurface and a cushioning layer. The cushioning layer comprises one ormore pouches with a filler material, and preferably a liquid fillermaterial, that distributes the downward pressure of the occupant acrossa larger area of the seat. This distribution of downward pressurereduces or eliminates pressure points in the seat. The seat may alsoinclude an air mover assembly that facilitates the heating, cooling orventilation function of the seat by blowing air to or drawing air fromthe seat.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 shows a perspective view of one embodiment of a pouch useful in acushioning layer, the pouch having through holes;

FIG. 2 shows a top view of one embodiment of a ventilating insert with acushioning layer located on the occupant side of the insert;

FIG. 3 shows a perspective view of a non-ventilating insert with acushioning layer on a base layer;

FIG. 4 shows a cross section of a pouch in a non-ventilating insertattached using rivets;

FIG. 5 shows a cross section of a pouch in a non-ventilating insertattached using two-sided tape;

FIG. 6 shows a cross section of a pouch in a non-ventilating insertattached using welding to a polyurethane film;

FIG. 7 shows a cross section of a pouch in a non-ventilating insertattached using an adhesive;

FIG. 8 shows a cross section of a pouch in a non-ventilating insertattached using a sewing method;

FIG. 9 shows a top view of a pouch attached using a sewing method with aheating element.

DETAILED DESCRIPTION

Vehicle seats may comprise at least one temperature conditionedcomponent such as a seat component, a backrest component, a bolster, anarmrest, a headrest or the like. In one embodiment, the temperatureconditioned component is a non-ventilated component which does notutilize a mechanism to move air into, out of or through the component.Each non-ventilated component may provide heating, cooling orcombinations thereof to the occupant. For example, a heating element mayprovide heat to the occupant.

In another embodiment, the temperature conditioned component is aventilated component which utilizes a mechanism to move air into, out ofor through the component, such as a blower in an HVAC system of thevehicle or a blower in the seat. Each ventilated component may provideheating, cooling, ventilation or combinations thereof to the occupant.For example, a blower may blow cooled air from a thermoelectric deviceto the occupant.

Each temperature conditioned component comprises a cushion and a trimsurface to cover the component, as well as an insert. The insert may bea non-ventilating insert or a ventilating insert. The present inventionrelates to a cushioning layer for incorporation into the seat, andpreferably, for attachment to or incorporation into the insert.

As seen in FIG. 1, the cushioning layer may comprise at least one pouch10 or bag of two or more layers 12, 14 of material that form containinga filler material (not shown), where a seal 16 is used to preventagainst leakage of the filler material. The material of the pouch isselected to be leak proof (vis a vis the filler material) and to havesufficient durability to withstand repeated entering and exiting of theseat by the occupant. The illustrated seal is a perimeter seal with aflange 18 of material external to the seal to facilitate attachment ofthe pouch to the other components of the insert or seat. In an alternateembodiment, a single layer of material is sealed to itself to form thepouch. Internal to the seal, the pouch may include one or more baffles20, where the baffles are points, lines or areas where the two layers ofthe pouch are attached to one another. For ventilating components, andas illustrated in FIG. 1, the baffles may also be a through hole 22 inthe pouch to allow air movement from one side of the pouch to the other.

The filler material in the pouch helps distributes vertical pressureexerted by the occupant of the seat in manner that reduces or eliminateslocalized pressure points of the occupant on the seat. When an occupantsits in a seat, the occupant's body contacts the seat in a limitedmanner in that the majority of the occupant's weight is placed in asmall area. For example, the occupant's hips and pelvis support themajority of the occupant's weight in a sitting position, leading topressure points. The pressure points, over time, may lead to discomfortof the occupant. The use of a cushioning layer helps reduce or eliminatethe discomfort associated with the pressure points, thus allowing theoccupant to sit for longer periods of time or otherwise reducing thefatigue associated with long periods of sitting. For example, thecushioning layer may distribute the vertical pressure from the occupantin a horizontal manner.

The characteristic of the filler material that is important is that itdistributes pressure exerted by an occupant throughout the material. Thefiller material of the cushioning layer may be in any physical state,whether liquid, gelatinous, solid or otherwise and combinations thereof.Suitable filler materials include neat water and combinations of waterwith agents that suppress the freezing point of water such assurfactants or heat transfer fluids. For example, freezing pointsuppression agents may contain a non-ionic surfactant like a polyol(e.g. a glycol or a polyglycol), with those having a molecular weight ofthan 350 being more suitable. Suitable glycols and polyglycols includepolyethylene glycols.

The filler material preferably remains a liquid across a larger range oftemperature such as between −40° C. to above 100° C., although this isnot necessarily the case.

Combinations of water and freezing point suppression agents suitablyhave a viscosity that ranges from about 0.01 cP to about 2.00 cP, with arange between about 0.50 cP and about 1.50 cP being more suitable, and arange of between about 0.90 cP and about 1.10 cP being most suitable.Moreover, the viscosity of the filler material is relatively temperatureindependent. A preferred filler material is Liquicell® from LiquiCellTechnologies of Eden Prairie, Minn.

In one embodiment, the filler material may be contained in a relativelyplanar pouch (e.g. a perimeter sealed pouch). The inclusion of bafflesis used to limit the movement of the filler material within the pouch,which helps to minimize pressure build up in the pouch away from thepressure points created by the occupant. The baffles may be a web ofmaterial located in the pouch that at least partially restricts the flowof the filler material through the pouch where the web material islocated. Alternately, the baffles may include one or more seal points,lines or areas where the layers of the pouch are sealed together tocreate obstructions to the flow of the filler material. The pouch mayinclude one or more through holes through which air may be moved. Thethrough holes would typically be aligned with ventilation holes in theremainder of a ventilating insert. Because the edges around the throughholes are sealed against leakage, they may also act as baffles.

Typically, the insert will include at least one other layer besides thecushioning layer, and preferably multiple (e.g. three) layers. Each ofthe layers may be a monolayer or a plurality of layers (e.g. alaminate). The plurality of layers need not be attached to each otherbut preferably are. More preferably, non-ventilating inserts include abase layer, a temperature conditioning device and the cushioning layer.More preferably, ventilating inserts include layers that are attached toeach other at least at their edges to form an edge-sealed bag, althoughthis is not necessarily the case as open edged ventilating inserts arealso suitable. The layers of the insert are typically co-extensive,although partial layers that are not co-extensive with the other layersor the insert are also suitable.

The insert and the layers that make up the insert have a seat portionand, optionally, an extension in ventilating inserts. The seat portiongenerally is the area of the insert that will provide temperatureconditioning (e.g. heating, cooling, ventilation or combinationsthereof) to the area of the seat used by the occupant, whether theinsert is located in the seat component, in the armrest component, inthe bolster or elsewhere. The extension permits the air movingcomponents of a ventilating system that includes the insert to be remotefrom the seat portion. This allows the components to be convenientlylocated so that they do not interfere with the comfort of the seat. Forexample, the extension permits fluid movers and/or thermoelectric deviceto be located underneath the cushion where they will not be noticeableto the occupant, underneath being relative to the occupant side of theinsert. While typically the extension is located at the back edge of theseat, it may be located on either side, in the front of the seat, on acorner or absent altogether. Multiple extensions may also be used on aninsert. To save on materials, the cushioning layer preferably does notinclude an extension, but rather covers an area up to being co-extensiveto an area covered by an occupant sitting or resting on the component.In one embodiment, the cushioning layer covers an area that is generallyco-extensive with a seat portion of a seat component.

Typically, the insert is supported by a cushion. The cushion may includeone or more ducts that extend partially or completely through thecushion, or the cushions may be free of ducts that extend through thecushion. A preferred cushion is a molded plastic foam, which ispreferably free of a molded or cut-out fluid distribution ductingnetwork, but may be adapted with a trench or opening for passing theextension from one side of the cushion to the another side (e.g. fromtop to bottom). The cushion may in turn be supported by a seat frame.Multiple inserts may be used on a single seat or backrest cushion, whereinserts may accomplish the same or different functions (e.g. one insertmay only cool, while another insert may both heat and cool). Further,one insert may include a cushioning layer while another does not.

In an alternative to the extension of the insert, a bellows or otherconduit may be used to provide connection between the insert and the airmoving components of the system. The bellows provides similarfunctionality as the extension, e.g. to permit components of the systemto be conveniently located remotely from the occupant contacts areas ofthe seat. The bellows or conduits may be located in a duct extendingthrough the cushion that supporting the insert. Thus, the bellows may belocated underneath the seat portion of the insert or connected to anedge of the insert. As with the extension, two or more bellows may beused in conjunction with each insert, each in a separate duct throughthe cushion or the ducts sharing one or more bellows. The bellows arepreferably connected to the insert in a relatively air tight manner,such as through a snap-fit attachment mechanism. In an alternateembodiment, an air moving assembly is directly attached to the insert.For example, one or more blowers may be attached to the non-occupantside of the insert, with those blowers placed in recesses in thecushion. Such an embodiment eliminates the need to supply a duct orconduit between the blowers and the insert.

For non-ventilating inserts, the base layer may be made of any suitablematerial to which a temperature conditioning device (e.g. a resistancewire heater) may be attached. Thus, the base layer may be any materialthat is dimensionally stable enough to hold the temperature conditioningdevice and cushioning layer in place through the repeated use of thecomponent (e.g. occupant entering and exiting a seat). Suitable baselayers include spacers (described below), foams (e.g. open cell foam,closed cell foam, etc.), films (e.g. polymeric films), textiles (e.g.felts or fabrics), combinations thereof and the like.

For ventilating inserts, one or more barrier layers may be included inthe insert and are typically formed of a plastic or polymeric material(e.g. a film) that may soften or melt upon exposure to heat or radiofrequencies to assist the layers to adhere to one or more other layersin the insert. Alternatively, the barrier layers may be formed offabrics, woven materials (e.g. Gore-Tex or microfibers), nylon, closedpore foam or other materials. Preferably, the barrier layers aresubstantially impermeable to air. Dimensionally, for a film barrierlayer, it is preferable for the filmthickness to be about 0.1 mm toabout 2.0 mm thick and more preferably about 0.7 mm to about 1.0 mmthick. Of course, it is contemplated that the film barrier layer mayhave a variable thickness and may be outside of the aforementionedranges. The barrier layers may include through holes to permit air flowacross the barrier layers such as ventilation holes or ports.

The ventilating insert may include a spacer, which may be locatedbetween two barrier layers of the insert. The spacer may be anystructure, material or combination of materials and/or structures thatpermits fluid flow through the material while also providing a measureof support for a seat occupant. The spacers should not collapse underthe weight of a seat occupant and maintain the fluid communicationthrough the spacer. As one example, the spacer may include rubber, foamplastic or the like. In one aspect, the spacer may include a reticulatedfoam.

The spacer may include a plurality of members or fibers that arepreferably spaced apart from each other to provide open spacetherebetween while still being close enough together to provide cushionand support. One preferred spacer is formed of polymeric (e.g.,polyester) strand material that is interwoven to provide opposinghoneycomb structures (e.g., fabric panels), which are interconnected byseveral additional polymeric strand materials to provide open spacebetween the structures while still providing cushion and support. As anexample, one preferred material is sold under the tradename 3MESH® andis commercially available from Müller Textil GmbH, Germany or MüllerTextiles, Inc., Rhode Island, USA.

Another preferred spacer is formed of a polymeric material in a helixheld between two sheets of material. Preferably, the helix is oblong inorder to provide increased area on the helix for attachment of the helixto the sheets of material. The helix may be tightly wound such thatadjacent courses of the helix touch or loosely wound such that there isno touching of adjacent courses of the helix. Typically, multiplehelices are placed adjacent (abutting or otherwise) to one another inorder to form a spacer. Exemplary helical material is discussed ininternational applications PCT/DE04/000540 and PCT/DE04/000541, bothfiles Mar. 17, 2004, both of which are incorporated by references.

The insert of the present invention may be a separate unit that isassembled in a space between a seat cushion and the trim surface,integrally formed in the seat cushion, integrally formed in the trimsurface, or any combination thereof.

One or more adhesive layers may be used to assist in the assembly of theinserts. The adhesive layers are preferably formed of a hot meltadhesive although this is not necessarily required. The adhesive may beprovided as a web or otherwise and may be continuous or non continuous(e.g., may be applied in drops, dabs or the like). The adhesivesub-layers may include polyamides, polyesters, elastomers, urethanes,olefin polymers or a combination thereof. Moreover, the adhesives may beformulated as desired for particular processing parameters orconditions. Preferably, the adhesive sub-layers are substantially freeof anti-blocking solutions, blowing additives, process contaminants orthe like which might interfere with adhesive performance. As an example,one suitable hot melt adhesive is commercially available as a non-wovenweb under the tradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane,Cuyahoga Falls, Ohio 44223. Other techniques instead of or in additionto adhesive may be used, such a thermal, ultrasonic, or RF welding.

The temperature condition device may be attached to or incorporated intothe insert. For example, the temperature conditioning device may be aheater. Various different types of heaters are suitable forincorporation into a car seat and it is contemplated that any of suchheaters may be incorporated into the inserts of the present invention.Such heaters typically incorporate flexible, electrical heating elementsthat are preferably thin, flat, non-obtrusive or a combination thereof.As examples, a lay-wire heater, a resistance wire heater, a carbon fiberheater, a positive thermal coefficient (PTC) heater, a thermoelectricheater or the like, which are typically supported with a backing (e.g.,a cloth or fabric type backing) may be used within the insert. In apreferred embodiment of the non-ventilating insert, the backing of theheater is the base layer for the insert. In a preferred embodiment, theheater is a carbon fiber type heater with a backing (e.g., a non-wovenlayer). One exemplary preferred heater is sold under the tradenameCARBOTEX® and commercially available from W.E.T. Automotive Systems,Inc. in Germany. An example of such a heater is disclosed in U.S. Pat.No. 6,064,037, issued May 16, 2000, herein expressly incorporated byreference for all purposes.

The temperature conditioning device may also be a heater/coolercombination such as a plurality of thermoelectric devices (TEDs) or aflexible sheet of TEDs. Flexible sheet TEDs include those discussed inU.S. Pat. No. 6,700,052, which is incorporated by reference. TEDs arediscussed in more detail below. Further, the temperature conditioningdevice may also be a cooler, such as those described in U.S. provisionalapplication 60/505,806, filed Sep. 25, 2003, which is incorporated byreference. Other coolers include phase change materials (PCMs),particularly those that have a phase change temperature near human bodytemperature. Such materials will absorb large amounts of heat withoutchanging temperature, thus providing a cooling sensation to theoccupant. Suitable materials include those provided by Rubitherm(Kyritz, Germany), PCM Energy (Mumbai, India) and Climator AB (Skovde,Sweden).

In addition to the heater or other temperature conditioning deviceattached to or incorporated into the insert, the temperatureconditioning device may be included in a ventilating system thatprovides heating, cooling, ventilation or combinations thereof.Typically, the temperature conditioning device is combined with an airmover assembly as a means for moving air into, out of or through theinsert, ventilated component or seat. In addition, one or more conduitsmay be used to provide fluid communication between components of thesystem such as between the fan and the insert or between the insert andthe temperature conditioning device.

The air mover assembly provides motive force to move air (whetherconditioned, ambient, pushed, pulled and combinations thereof) to, fromor through the insert. The assembly may be used to push air to theinsert or pull air from the insert. The assembly may also be used toboth push and pull air. For example, an assembly with a blower having atleast two sets of fan blades (e.g. with vanes that are opposite indirection) that share a common axis and form a binary blower that isable to both push and pull air may be used. Multiple blowers may also beused in the assembly. The assembly may also include an annular inlet,although assemblies that are free of annular inlets are alsocontemplated. Included in the definition of blower are impellers(including bidirectional impellers), blowers, or the like. The bloweralso refers to devices that provide motive force to move other fluids(e.g. liquids) through the insert. The blower may provide a steady fluidflow, a pulsating fluid flow, an oscillating fluid flow, or the like.

The temperature conditioning device used with the ventilating insert maybe any device that heats and/or cools fluid. The device may be acombination of devices where one component provides heating and anothercomponent provides cooling (e.g. as resistance wire heater and athermoelectric device). Preferably, one device or system provides bothheating and cooling. The device may be an external device such as theHVAC system in the building or vehicle where the seat is located or aninternal device meaning that the device is not connected (other than toa power supply) to the building or vehicle where the seat is located. Inaddition to providing temperature conditioning, the temperatureconditioning device may also dehumidify the fluid (e.g. air).

Preferably, the temperature conditioning device is a self contained orsolid state device that both cools and heats air. The most preferreddevice is a TED (also called a peltier). TEDs are commercially availabledevices that provide solid state heating and cooling by passingelectricity through the device. TEDs include a waste side and an activeside, which are relative designations depending whether warm or cooltemperature conditioned air is desired. Any supplier of TEDs would beable to provide suitable devices for use in the present invention. TheTED may be combined with any useful heat dissipation device; e.g. heatsinks, heat exchangers, blowers, heat pipes or the like. A refrigerationabsorption system may also be used as a temperature conditioning device.

The ventilating system may include one or more attachment componentsused to help secure the insert or portions of the system to the insert,the cushion, the seat frame or the seat. For example, a frame memberpreferably defines a location for the attachment of the air moverassembly, temperature conditioning device, a conduit, a bellows or othercomponent to the insert. It is contemplated that the frame member may bein a variety of configurations (e.g., annular, rectangular, square,polygonal or otherwise) and may be formed of a variety of preferablyrigid or semi-rigid materials (e.g. metal, plastic or the like). In someaspects, the attachment component also helps define a port in the insertor extension. In one preferred embodiment, the attachment componentcooperates with structures and/or materials (e.g. snap fit fasteners) onthe blower, the temperature conditioning device or other components toconnect the device or component to the attachment component.

The ventilating system may include one or more valves that may be usedto redirect air flow through the system to make use of unused energy(i.e. the air is hotter than ambient) or energy capacity (i.e. the airis colder than ambient) in the air. For example, the valves may be usedto vent air to ambient to dispose of un-needed energy stored in the air.The valves may also be used to redirect air to components of the system(e.g. the temperature conditioning device) to either warm or cool suchcomponents. In addition, a valve may be used to optionally recirculateair within system to create a closed or partially closed system.

For both ventilating and non-ventilating embodiments, a variety ofsensors may be included such as temperature sensors, humidity sensors,current sensors, occupant detection sensor, weight sensors or the like.Sensors may be placed throughout the seat. For example, temperaturesensors may be place within the spacer, between spacers, between thespacer and the cushioning layer, between the base layer and thetemperature condition device or other optional layer (e.g. reticulatedfoam or seat cover), near the temperature conditioning device, near theblower, and combinations thereof.

One or more controllers may be used to receive inputs from the sensorsor a control device, to issue instructions to the blower and/ortemperature conditioning device, and/or to otherwise coordinate theoperation of the system.

Suitable trim surfaces include seat covers that are part of the insertor separate from the insert, but generally separate the insert from theseat occupant. The trim surface may be any suitable material, includingbut not limited to at least one synthetic material, natural material(e.g., wool, leather or otherwise), or combination thereof. In oneembodiment the trim surface includes perforations over at least aportion of the seating surface through which air or other fluid maypass. In another embodiment the cover is substantially free ofperforations. For example, perforated or non-perforated leather may beused to separate the seat occupant from the insert, while a fleecematerial may be used as part of the insert to increase moisture wickingor otherwise provide a protective layer.

The cushioning layer may be integral with the insert such that they forma single component that may be incorporated into the seat. For example,the cushioning layer may be attached through the use of an adhesive(e.g. spray on or double stick tape) or through mechanical fasteners.Exemplary mechanical fasteners include rivets, snap-fit fasteners,hoop-and-loop fasteners, sewing, tie downs or the like. The cushioninglayer may also be welded through the use of heat, RF, IR or ultrasonicwelding of two plastics together. Alternately, the cushioning layer maybe integral, attached to the trim surface or held within a pocket ofmaterial attached to the trim cover to ease installation. Alternately,the insert, cushioning layer and/or the trim surface may be held inposition through the use of tie downs that anchor the components to thecushion or frame of the seat.

While the figures illustrate specific embodiments of the presentinvention, the figures are not meant to be limiting.

FIG. 2 illustrates a top view of a ventilating insert 30 that may beused in a ventilated seat that provides heating, cooling and/orventilation to the occupant. The insert comprises an edge sealed bag 32of a spacer sandwiched between two barrier layers. Attached to theoccupant side of the edge sealed bag are a plurality of pouches 34 thatmake up the cushioning layer 36. Each of the pouches includes one ormore through holes 38 that align with ventilation holes in the occupantside of the edge sealed bag. Additional ventilation holes 40 that do notalign with through holes in the pouches may also be included in the edgesealed bag. A through hole 42 that is sealed from the rest of the edgesealed bag may be used with a tie down to secure the insert to thecushion or seat frame.

FIG. 3 illustrates a perspective view of a non-ventilating insert 50.The pouches 52 of the cushioning layer are arranged on base layer 54. Awiring harness 56 is used to connect the heating element (not shown)contained within the base layer to the electrical system of the vehicle.

As seen in FIGS. 4-8, the pouches 60 having two layers 62, 64 with afiller material 66 may be attached to the base layer 68 using a varietyof methods. These same methods may be used to attach pouches to thesealed edge bag of a ventilating insert. In FIG. 4, shown in crosssection, rivets 70 are placed on the flange 72 outside the perimeterseal 74 of the pouch 60. The rivets penetrate the flange and theremaining layers of the insert or base layer; in this embodiment, thebase layer 68 includes a felt layer 76 and a foam layer 78. A heatingelement 80 is located between the felt and foam. Rivets may also be usedin any baffles so long as they do not permit leakage of the fillermaterial.

In FIG. 5, shown in cross section, two-sided tape 8 is used between thepouch 60 and the base layer 68. Unlike the rivets, the placement of thetwo-side tape is not limited to the flange or baffles. In thisembodiment, the base layer comprises a heating element sandwichedbetween a felt layer and a foam layer.

In FIG. 6, shown in cross section, a weld 84 is used to attach the pouch60 to the base layer 68. Preferably, an RF welding technique is used toconnect a polyurethane containing (or other thermoplastic containing)portion 86 of the base layer 68. Welding is preferably only used on theflange or baffles of the pouch as it may puncture or otherwisecompromise the integrity of the pouch.

In FIG. 7, shown in cross-section, an adhesive 88 is used to attach thepouch 60 to the base layer 68. While preferably applied to align withthe perimeter seal of the pouch, the adhesive may be applied in manydifferent suitable patterns to insure secure attachment of the pouchesto the base layer. The adhesive may be any suitable adhesive asdescribed above.

In FIG. 8, shown in cross-section, a sewn thread 90 is used to attachthe pouch 60 to the base layer 68. Like rivets, sewing penetrates theflange and the remaining layers of the insert or base layer. Sewing ispreferably only used in the flange or baffles of the pouch. For sewingand other techniques that penetrate the flange or baffle, care should betaken not to damage the heating element contained within the base layeror insert. For example as seen in FIG. 9, the sewn thread 90 has gaps topermit the heating element 92 to enter and exit the area under thepouch. This figure also illustrates baffles 94 without through holes inthe form of spot welds.

In one embodiment of the cushioning layer combined with a ventilatinginsert, the underside of the cushioning layer forms the forward barrierlayer of the insert. For example, a cushioning layer that comprises aplurality of pouches attached to a plastic film may be used as a barrierlayer for an insert. Such a construction would reduce the number layersneed to construct a ventilating insert and thus also reduce the cycletime for the manufacturing of the insert. Furthermore use of plasticfilms in the cushioning layer would permit the use of RF or other typesof welding, further reducing the cycle time. A heater included in thistype of embodiment may be attached to either side of the plastic film orto the spacer within the insert. Alternately, the heater (e.g. a PTCheater) may be printed on the plastic film. In one preferred embodiment,no adhesive is utilized in the construction of the insert, but ratheronly welding is used.

In addition to the embodiments discussed above, the cushioning layer mayalso be added on to the seats of U.S. Pat. Nos. 6,786,541; 6,629,724;6,840,576, 6,869,140, and related applications and patents or to theseats of U.S. Patent Publication 2004-0189061. In addition, thecushioning layer may used in combination with the seats of U.S. Pat.Nos. 6,893,086; 6,869,139; 6,857,697; 6,676,207; 6,619,736; 6,604,426;6,439,658; 6,164,719; 5,921,314, and related applications and patents,or U.S. Patent Publications 2005-0173950; 2005-0161986; 2005-0140189;2005-0127723; 2005-0093347; 2005-0085968; 2005-0067862; 2005-0067401;2005-0066505; 2004-0169028, and related applications. All patents andpublications are hereby incorporated by reference. Further, thecushioning layer may be used as a substitute for components of theseseats.

In one embodiment, temperature conditioned air may be blown across theoccupant through a permeable trim surface from the seat cushion thusproviding convective heating or cooling to the seat and occupant. Asshown in U.S. Pat. Nos. 6,869,139 and 6,857,697, the cushion may containa passageway through the cushion for circulating temperature conditionedair to the seat surface through the insert. A variety of other optionalfeatures disclosed in these patents may be included in the seat systemsof the present invention, such as sub-passageways, deflectors,air-impermeable linings or coating or the like. For example, an insert(e.g. an open edged insert) with through-holes may be placed over thesub-passageways to moderate or direct the air blown on the occupant. Thecushioning layer in this system would include through holes so as to notimpede the flow of air from the cushion to the occupant. A certainamount of conductive cooling may also be achieved through the use ofthis system.

In another embodiment, conductive heating or cooling may be provided tothe occupant by providing temperature conditioned air to the insert suchthat the air is not blown across the occupant. For example, through theuse of an air impermeable trim surface, temperature conditioned air iscirculated to an insert having an open space is located underneath theimpermeable trim surface, with air blown or drawn into the insert forthe purpose of conductively heating or cooling the insert and thus theoccupant. Here, if the cushioning layer is located between the trimsurface and insert, it need not include through holes.

In another embodiment, conductive and convective heating or cooling maybe provided to the occupant. The temperature conditioned air may becombined with ambient air drawn across the occupant and into the seat.Here, ambient air is drawn through the trim surface and into a mixingregion underneath the trim surface where the ambient air is combinedwith the temperature conditioned air. The mixed air is then circulatedaway from the seat either to be exhausted or to be recirculated back tothe evaporator and/or the mixing region. The ambient air providesconvective cooling (or heating), while the temperature conditioned airprovided conductive cooling or heating. A plurality of air movers may beused to draw ambient air into the mixing region and to providetemperature conditioned to the mixing region, whether by blowing ordrawing. In one embodiment, the mixing region is an open space containedin an insert. Examples of seats comprising mixing regions include U.S.Patent Publication 2005-0067862 and 2005-0066505. Preferably, thecushioning layer is located between the trim surface and insert in thisembodiment.

Although discussed in the context of a vehicle seat, the temperatureconditioned components of the present invention may be incorporated intoany type of seat or chair such as office chairs, wheel chairs,furniture, or any other seat where the occupant may benefit for thereduction of the discomfort associated with long term sitting.

The present invention also relates to methods of heating, cooling andventilating a vehicle seat. The methods comprise heating or cooling aseat comprising a cushioning layer. The methods also comprisecirculating air from a temperature conditioning device into, out of orthrough an insert, ventilated component or a seat.

It will be further appreciated that functions or structures of aplurality of components or steps may be combined into a single componentor step, or the functions or structures of one-step or component may besplit among plural steps or components. The present inventioncontemplates all of these combinations. Unless stated otherwise,dimensions and geometries of the various structures depicted herein arenot intended to be restrictive of the invention, and other dimensions orgeometries are possible. Plural structural components or steps can beprovided by a single integrated structure or step. Alternatively, asingle integrated structure or step might be divided into separateplural components or steps. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention. The present invention alsoencompasses intermediate and end products resulting from the practice ofthe methods herein. The use of “comprising” or “including” alsocontemplates embodiments that “consist essentially of” or “consist of”the recited feature.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the invention. The scope of the inventionshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes.

1. A temperature conditioned seat, comprising: a seat having at leastone temperature conditioned component having a cushion and a trimsurface; an insert located beneath the trim surface of each temperatureconditioned component, the insert including a cushioning layer locatedbetween the cushion and the trim layer; and a temperature conditioningdevice.
 2. The seat of claim 1 wherein the cushioning layer comprises atleast pouch containing a filler material.
 3. The seat of claim 2 whereinthe filler material is a liquid.
 4. The seat of claim 3 wherein theliquid comprises a freezing point suppression agent.
 5. The seat ofclaim 4 wherein the temperature conditioned component is anon-ventilating component.
 6. The seat of claim 5 wherein thetemperature conditioning device comprises a heater.
 7. The seat of claim6 wherein the heater is located between the cushion and cushioninglayer.
 8. The seat of claim 4 wherein the temperature conditionedcomponent comprises a ventilating component.
 9. The seat of claim 8wherein the ventilating component comprises an air mover.
 10. The seatof claim 9 wherein the temperature conditioning device comprises asource of cooled air.
 11. The seat of claim 10 wherein the source ofcooled air comprises a vehicle HVAC system, an absorption refrigerationsystem, a thermoelectric device and combination thereof.
 12. A vehicleseat, comprising: a seating component comprising a cushion and a trimsurface; a cushioning layer located between the cushion and the trimsurface, comprising: a plurality of edge sealed pouches containing afiller material attached to a base layer; and a heater locatedunderneath the pouches and attached to the base layer.
 13. The vehicleseat of claim 12 wherein the filler material is liquid with a viscosityof about 1 cP.
 14. The vehicle seat of claim 13 wherein the base layercomprises a foam or a film.
 15. The vehicle seat of claim 14 wherein thepouches are attached to the substrate using one or more of mechanicalfasteners, two-sided tape, adhesive, sewing, IR welding, RF welding orultrasonic welding.
 16. The vehicle seat of claim 15 further comprisinga ventilating insert.
 17. The vehicle seat of claim 16 wherein thecushioning layer and the insert are an integrated component.
 18. Thevehicle seat of claim 17 further comprising a temperature conditioningdevice and an air mover assembly.
 19. The vehicle seat of claim 18wherein the temperature conditioning device comprises a thermoelectricdevice.
 20. The vehicle seat of claim 19 wherein the air mover assemblyblows air through the ventilating insert to an occupant of the seat.